Interconnected solar module design and system

ABSTRACT

A frame assembly is provided for a solar module. The frame assembly includes a plurality of frame members that are structured to collectively support and hold a first solar panel. At least one of the plurality of frame members is structured to adjoin a frame member of a second solar module in forming a joining with the frame member of the second solar module over a length where the frame member of the first and second solar module adjoin.

PRIORITY APPLICATIONS

This application claims benefit of priority to Provisional U.S. PatentApplication No. 60/747,593, filed May 18, 2006, entitled DESIGN FORINTERCONNECTING SOLAR MODULES; the aforementioned priority applicationis hereby incorporated by reference in its entirety for all purposes.

This application also claims benefit of priority to Provisional U.S.Patent Application No. 60/824,744, filed Sep. 6, 2006, entitled METHODOF INSTALLING MOUNTING CHANNELS ON BUILDING FACADES; the aforementionedpriority application being hereby being incorporated by reference.

This application also is a continuation-in-part of U.S. patentapplication Ser. No. 11/332,000, filed Jan. 13, 2006, entitled RACKASSEMBLY FOR MOUNTING SOLAR MODULES; which (i) claims benefit ofpriority to Provisional U.S. Patent Application No. 60/643,619, filedJan. 13, 2005, entitled PV/THERMAL INTEGRATED ENERGY SUPPLY SYSTEM, and(ii) is a continuation-in-part of U.S. patent application Ser. No.10/855,254, filed May 26, 2004, entitled MECHANISM FOR MOUNTING SOLARMODULES, which claims benefit of priority to U.S. Patent Application No.60/544,753, filed Feb. 13, 2004, entitled SYSTEM, METHOD, AND APPARATUSFOR MOUNTING A SOLAR MODULE. All of the aforementioned priorityapplications named in this paragraph are hereby incorporated byreference in their entirety for all purposes.

TECHNICAL FIELD

The disclosed embodiments relate generally to the field of solarmodules. In particular, the disclosed embodiments relate tointerconnected solar modules and a system for interconnecting solarmodules.

BACKGROUND

Modules for converting solar energy into useful forms of energy such asheat and electricity have been in existence for many years. Because ofthe sun's low energy intensity and the moderate conversion efficiency ofsolar modules, a large array of solar modules is often required toservice the end-use of the energy. Array areas from several dozen squarefeet to several thousand square feet are common. A thermal solar modulemay consist of a glazing surface and an absorber below the glazingsurface. A perimeter frame is usually used to fix the glazing surfaceand absorber in relation to one another and to serve as a structuralelement for the thermal module. Moreover, the variety of surfaces onwhich the modules may be mounted requires a wide range of flexibilityand adaptability in the methods of interconnecting the solar modules toform an array.

Another example of a solar module is a solar photovoltaic (PV) module,which consists of a series of PV cells connected in a series andparallel combination to yield a specific current and voltage output. Dueto the fragility of the cells and the harsh environmental conditionsthey are often exposed to, the assembly of cells is often encapsulatedinto a rigid laminate. Most PV laminates are fabricated from a glasscover, an active layer containing the PV cells, and a back cover. WhilePV laminates can be directly attached to a mounting structure, it ismore common for them to be framed before mounting. PV laminate framestypically consist of aluminum extrusions with an upper cavity thatreceives the laminate when assembled. The frame serves the purpose ofincreasing the rigidity of the laminate and to protect the fragile glassedge of the laminate from cracking. Frames for PV modules often includea lower flange with pre-drilled holes for affixing them to mountingstructures.

Because PV modules must be electrically interconnected, they are oftenmounted in strings where the modules are assembled end to end to form arow of modules. Due to the fact that most mounting surfaces such asroofs are square or rectangular in nature, most PV module installationsconsist of multiple rows assembled in close proximity to match thegeneral footprint of the surface on which they are mounted. Sucharrangements of multiple rows of modules are generally referred to as anarray.

Solar PV modules are typically constructed of a simple metal framesurrounding the PV laminate sheet that encapsulates the active solarcells. The electrical connections representing the positive and negativemodule outputs are often provided in the form of quick disconnectconnections such as those manufactured by Multi-Contact of Santa RosaCalif. These quick-disconnect fittings are usually provided on the endsof lead wires 2-4′ in length to allow two adjacent PV modules to beconnected together.

The assembly of loose connections results in wasted time during theassembly of the solar PV modules into a larger array as the fittingsmust be found, connected, and any slack in the lead wires must be coiledand secured to prevent possible abrasion and shorting against theunderlying mounting surface. Additionally, to prevent the quick-connectsfrom coming undone in the field, some variants employ locking featuresat additional cost and complexity of installation.

In addition to connecting the voltage outputs of each solar PV module,most some electrical codes require that the module frames themselves beelectrically grounded. This is often achieved by fixing a bare copperconductor to each module frame by means of a screw and washer. Thegrounding of module frames can be as time consuming as the wiring of thevoltage outputs.

When installing the modules outlined above into a racking system, aspecific order of assembly is often performed. When installing multiplemodules, one often places the new solar PV module on the rack a few feetfrom the previously installed solar PV module. Then one must stepbetween the two modules and reach underneath the previously installedmodule to acquire the free lead wire from the back of the module andthen reach underneath the new module and acquire the wire of the desiredpolarity from the back of the new module and connect these two wires.The connectors are usually of the quick-disconnect type described aboveand require two free hands to connect, which can be problematic if aspare hand is necessary to hold tooling or an unsecured module on asloped roof. The loose wire on both modules should be neatly coiled upand tied with twist ties or zip ties. The wires also should be preventedfrom touching or resting on the roof. Over time, wind will brush thewires across the roof surface and abrade the insulation causing exposureof the conductor and possible shorting.

Keeping to some electrical codes, all modules must be grounded to anacceptable ground source. Therefore the new module must be grounded tothe entire array by connecting it to a separate bare grounding wire thatis running through the array. The grounding wire would be attached tothe previously installed module and the loose end must be brought closeto the mounting position on the new module. A wire clamp must beattached to the frame of the new module with a screw. Then the wire mustbe looped through the wire clamp on the new module and then fastenedinto the clamp.

In the last step, one must step away from the gap between the twomodules and the new module is pushed up against the previous module andmounted to the racking structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a simplified illustration of solar panels together withassociated frame members assembled into an array and constructed underone or more embodiments of the invention.

FIG. 1B illustrates an implementation of an embodiment shown by FIG. 1A.

FIG. 1C illustrates an assembly for securing a solar module array to anunderlying surface, under an embodiment of the invention.

FIG. 2 is a side view of array 100, as mounted on an underlying surface210, according to one or more embodiments of the invention.

FIG. 3 illustrates path flows of water from rain flow, when array ismounted to an inclined surface, under an embodiment of the invention.

FIG. 4 is a top view of a frame assembly formed from a set of framemembers and constructed to support a solar panel, according to anembodiment of the invention.

FIG. 5A is a side-cross sectional view of a first pair of adjoininginterior frame members in an assembly for a solar module array,according to an embodiment of the invention.

FIG. 5B is a side-cross sectional view of a second pair of adjoininginterior frame members in an assembly for a solar module array,according to an embodiment of the invention.

FIG. 6 is an isometric view of an embodiment such as shown by FIG. 5Aand FIG. 5B, without inclusion of solar panels.

FIG. 7 illustrates an alternative embodiment in which an additionalcomponent or member is provided to seal or provide flashing betweenadjoining frame members, according to one or more embodiments of theinvention.

FIG. 8 illustrates an alternative embodiment in which a gasket orsimilar component is fitted or applied into a gap between the horizontalframe members of adjacent solar modules, according to one or moreembodiments.

FIG. 9 illustrates an embodiment in which flashing and other structuresare used to guide water over the solar modules.

FIG. 10 is a side view of adjacent solar modules having integratedelectrical connectivity extending therebetween, under an embodiment ofthe invention.

FIG. 11 is an isometric view of an embodiment of FIG. 10.

DETAILED DESCRIPTION

Embodiments described herein provide a solar module assembly, andprimary support structures for supporting solar modules in an assembly,that prevent or hinder intrusion of water or debris within a gap that isformed by adjacent solar modules.

An embodiment includes a frame assembly for a solar module. The frameassembly includes a plurality of frame members that are structured tocollectively support and hold a first solar panel. At least one of theplurality of frame members is structured to adjoin a frame member of asecond solar module in forming a joining with the frame member of thesecond solar module over a length where the frame member of the firstand second solar module adjoin.

According to another embodiment, a frame assembly for a solar moduleincludes a plurality of frame members that are structured tocollectively support and hold a first solar panel. The plurality offrame members includes a first frame member that provides an overlapframe thickness a distance outward from the first frame member. Theoverlap frame thickness is extended outward in a lengthwise direction ofthe first frame member. The plurality of frame members includes a secondframe member that includes a perimeter recessed platform that isextended in a lengthwise direction of the second member, wherein therecessed platform is provided against an exterior surface of the secondframe member to define a depth distance between the recessed platformand the exterior surface.

In another embodiment, a solar module assembly includes a plurality ofsolar modules, primary support structures, and a sealing feature. Theframe assembly includes a plurality of frame members, including multiplesets of frame members. Each set of frame members may combine to supporta corresponding solar panel in position. The plurality of frame membersinclude a pair of adjoining frame members. The pair of adjoining framemembers include a frame member of a first set of frame members thatadjoins a frame member of a second frame member. The sealing featureprovided for the pair of adjoining frame members to substantiallypreclude intrusion of at least one of external air or water into a spaceunderlying a solar module of the first set or of the second set.

As used herein, the term “solar module” means the combination of a solarcollective panel (e.g. photovoltaic laminate containing solar cells,glazed component, or other absorber/generating elements) and framemembers that retain the panel. A solar module may utilize solar energyfor any purpose, including generating electricity (i.e. Solar PV) andthermal energy.

Overview

FIG. 1A is a Simplified Illustration of a Solar Panel AssemblyConstructed Under one or more embodiments of the invention. In anembodiment, an array 100 includes a plurality of frame members thatassemble to support and hold a collection of solar modules 110 inposition over an underlying surface. An embodiment of FIG. 1Aillustrates use of four solar modules 110 in a rectangular arrangement,although more or fewer solar modules may be used, and in differentconfigurations. As described, the underlying surface may correspond to arooftop or other similar surface. Though not required to be mounted onan inclined surface, one or more embodiments contemplate use of aninclined underlying surface for the mounting of the array of solarmodules.

FIG. 1A may be described in reference to a vertical and horizontaldirection. The designation of horizontal and vertical directions may bearbitrary, but for purpose of an implementation such as described withFIG. 1A, the vertical direction also coincide with the direction ofsupport structures for the array as a whole. In one embodiment, thearray 100 includes rails 135 or other primary support structures thatare vertically aligned. With this reference and configuration, the framemembers include vertical frame members 105 which extend co-linearly withthe rails 135, and horizontal frame members 106 which span between thevertical frame members 105. In one embodiment, vertical frame members105 are extended, integrated or coupled with rails 135 or other supportstructures. As mentioned, the rails 135 may form a primary securement ofthe array 100 against an underlying surface. The horizontal framemembers 106 extend between vertical frame members 105. In an embodiment,each column of the array 100 is separated by a rail 135, from which oneor more vertical frame members 105 are provided.

Within each column, rows comprising individual solar panels 110 adjoinone another via horizontal frame members 106. In an embodiment,adjoining horizontal frame members within a column are individually orpair-wise structured, or otherwise configured (e.g. through provision ofstructural or additional features), to form a joining 120. Suchadjoining horizontal frame members 106 are also interior frame members.As described with one or more embodiments, the joining 120 may abut thehorizontal frame members 106 in a manner that provides a seal orweather-proofing.

The array 100 may be defined by a perimeter or boundary that includes atop side 102, a pair of lateral sides 104, and a bottom side 106.According to an embodiment, at least some of the frame members 105, 106include or are combined with structures and/or features that seal orweather protect portions of the perimeter to the underlying surface. Inone embodiment, the frame members 105, 106 include and/or are combinedwith flashing and counter-flash structures that are supported on theunderlying surface. Portions of the perimeter that may be sealed includethe top side 102, as well as the lateral sides 104. As will bedescribed, the perimeter sealing may form one facet in a design in whichwater may be directed or moved over or around the solar modules 110while maintaining weather proofing for the assembly as a whole. Thewater may result from precipitation, or through the accumulation ofwater, ice or snow. Additionally, dirt or other unwanted debris may beincluded in the water.

Accordingly, horizontal frame members 106 that serve to supportadjoining solar modules 110 may be constructed or combined so as tocreate the individual joinings 120 along an edge of each adjoining solarmodules 110. With reference to an embodiment of FIG. 1A, the joinings120 provided by the combination of horizontal frame members 106extending horizontally. The joinings 120 in each column of array 100 mayseal or weatherproof the solar modules 110 against the environment,without need for glazing or glass layers or other additive thicknessesthat are applied over the modules or the array 100 as a whole.

In an embodiment, the joinings 120 are structural features that createflashing and counter-flashing edges between adjacent interior frames. Inanother embodiment, the joinings include or are otherwise provided byadditional members and/or features for sealing or flashing. Examples ofsuch additional members and/or features include gaskets, appliedsealants such as silicone, or joint members.

While an embodiment of FIG. 1A shows use of joinings in only onedirection (horizontally or spanning between rails 135) one or morevariations provide for use of joinings 120 of adjacent frame members inboth horizontal and vertical directions. For example, one or moreembodiments provide that adjacent columns of array 100 may be adjoinedand formed from frame members that include features for forming joiningsbetween solar modules of adjacent columns.

In an embodiment, the vertical frame member 105 that supports eachcolumn may be compressed or otherwise retain each solar module withinthe larger array so that it is sealed. For example, some or all of thevertical frame members 105 may coincide in position with a correspondingone of the rails 135. Each rail 135 may cause the corresponding verticalframe member to compress the solar module from the edge against the rail135, so as to seal that edge of the solar module into the array as awhole.

Alternatively, one or more embodiments provide for one or more of thevertical frame members 105 to use structural or additive features forsealing or weather-guarding individual solar modules in retention.

Any of the joinings 120 may provide seals that preclude entrance ofwater, air, or other elements of the environment. Alternatively, some orall of the joinings 120 may provide flashing by directing fluid withoutsealing the exterior formed by the solar modules.

In addition to joinings 120, one or more embodiments provide for the useof integrated electrical connectors (IEC) 130, 130 that extendelectrical connectivity from one module to another. The IEC 130 includeselectrical connectors embedded or otherwise integrated with verticalframe members 105 and/or horizontal frame members 106. The IEC 130 mayserve to provide multiple polarities, including ground, and/or carrycharge or current produced from any of the solar modules 110.

FIG. 1B illustrates an implementation of an embodiment shown by FIG. 1A.In FIG. 1B, array 100 comprises both solar photovoltaic modules 152which use solar energy to generate electricity, and thermal modules 154which use solar energy to generate heat. The combination may thus enableelectricity generation, heating, applications of heating, cooling, andapplications of cooling. A combination such as shown by an embodiment ofFIG. 1B may be combined and used with features and structures describedwith an embodiment of FIG. 1A. A mixed configuration such as illustratedby FIG. 1B may be used with any of the embodiments described herein. Theactual placement and arrangement of solar thermal modules 154 and solarphotovoltaic modules 152 within the array may vary.

In an embodiment of FIG. 1B, the IEC 130 may serve to connect adjacentphotovoltaic modules 152 and pass underneath thermal modules 154 withoutelectrical connectivity. Plenums (not shown) for carrying heat or airmay pass underneath thermal modules 154 for effect, while alsounderlying photovoltaic modules 152 as air is passed or pushed under thearray 100.

FIG. 1C illustrates an assembly for securing a solar module array to anunderlying surface, under an embodiment of the invention. In anembodiment, a primary support structure 170 includes a plurality ofsupport structure members. The support structure members include rails175, which secure one or more solar modules 110 to the underlyingsurface. The rails 175 may correspond or be equivalent to rails 135 suchas shown in FIG. 1A. As such, the rails 175 may be referenced asaligning vertically, so as to define vertical seams in a solar panelarray.

Each solar panel module 110 may include frame members 188 that supportand retain individual panels 192 (e.g. PV laminate) from the edge orboundary of the panel. In the horizontal and vertical referenceprovided, frame members 188 may extend horizontally between rails 175and vertically so as to be co-linear with rails.

The primary support structure 170 may be configured to support bothincline and flat mountings. With incline mountings, an embodiment ofFIG. 1C may be combined with one or more other embodiments describedherein to promote or facilitate the movement of water over the solarmodules 110. With flat mountings, an embodiment of FIG. 1C may becombined with other embodiments to inhibit intrusion of water and debrisinto an interior space between the underlying surface and the solarmodule array.

In an embodiment, each rail 175 includes a base member 180 and acompression member 182. The compression member 182 may secure to an edgeof a corresponding solar module 110. Bolts 184 or other mechanisms maybe used to compress the member 182 against the base member, therebysecuring the corresponding solar module 110 at one edge to the basemember 180. The base member itself may be secured directly or indirectlyto the underlying surface. In one embodiment, struts 190 may mounthorizontally (to the vertical direction of the rails 175) to theunderlying surface, and the rails 175 may mount to the struts 190.

The solar module array may be sealed or weather-proofed at the followinglocations: (i) between the primary support structure 170 and theunderlying surface; (ii) between the vertical frame members 188 and thesolar module 110; and (iii) between adjacent solar modules in thehorizontal direction.

In order to seal or weather-proof the support structure 170, the rails175 may be provided with flashing and/or a seal to the underlyingsurface, along a length of the rails 175. With reference to anembodiment of FIG. 1A, a length of the rails 175 may correspond to thelateral sides 104, 104 of the array 100. The primary support structure170 may also include one or more additional perimeter support member 177that span horizontally between the rails 175. With reference to FIG. 1A,the additional perimeter support member 177 may form the top side 102and may also be flashed or sealed against the underlying surface. Inaddition, corner elements 179 may be provided that join the spanningperimeter support member 177 and the rails 175. The corner elements 179may also include corner flashing or sealing against the underlyingsurface. U.S. patent application Ser. No. 11/332,000 (incorporated byreference herein), for example, provides various techniques forweather-proofing and flashing the primary support structure 170 in amanner described.

According to an embodiment, application of the compression member 182 tothe base member 180 while gripping or retaining an edge of solar module110 may be used to provide sealing or weather-proofing of the verticalseam formed between the vertical frame member 188 of the solar module110 and the rail 175 of the primary support structure. However, one ormore variations are contemplated, where gaskets or structures are usedto enhance or create a seal or weather-proofing between the primarysupport structure 170 and the solar module 110.

In order to seal or weather-guard the solar modules along the horizontalseams, one or more embodiments provide that the frame members 188 areprovided features or structural configurations for effectuatingflashing, shingling or sealing. Accordingly, the horizontal framemembers 188 (and/or the manner in which the horizontal frame membersadjoin one another) may be constructed according to any of theembodiments described below and elsewhere in this application.

With reference to embodiments of FIG. 10 and FIG. 11, FIG. 1C alsoillustrates the passage of electrical connectors 195 from one solarmodule 120 to another. The manner in which the electrical connectors 195may be combined or integrated with the frame members 188 of the solarmodules 120 is described below.

FIG. 2 is a side view of array 100, as mounted on an underlying surface210, according to one or more embodiments of the invention. Embodimentsdescribed herein enable solar modules 110 to be mounted to eitherweather-guard or seal interior spaces 220 against intrusions of air,water or other undesirable environmental elements. When the underlyingsurface 210 is inclined, the manner in which water (e.g. from rain flow)is handled with the presence of a solar array is of concern. In order toweather-proof or seal the interior spaces 220 from the environment, oneor more embodiments provide that water flow (e.g. from rain) is directedfrom the top side 102 downward so as to cascade across the surface ofthe solar modules 110. Embodiments allow for the passage of water overthe solar modules by including joinings 120 that preclude substantialintrusion of water into the interior space 220. As such, the array 100may be weather-guarded or sealed by a combination of (i) the joining 120between solar modules 110, (ii) the force provided by the rails 135 orother support structures through the vertical frame members 105 (whichare co-linear with the rails) to effect a seal between them, and (iii)the flashing or sealing of the rails 135 and other perimeter members tothe underlying surface,

FIG. 3 illustrates path flows of water from rain flow, when array 100 ismounted to an inclined surface, under an embodiment of the invention. InFIG. 3, one path of water flow is across solar module 110. As mentioned,the joinings 120 preclude or inhibit water from entering (substantiallyor completely) the interior spaces 220 (FIG. 2). One or more embodimentsalso facilitate and/or protect water flow around the array 100. Asdescribed below, vertical frame members 105 that are co-linear withlateral sides 104, 104 of array 100 may be flashed or sealed against theunderlying surface 210 to protect water seepage into the perimeter ofthe underlying space 220.

Structuring of Frame Members for Flashing Effect

FIG. 4 is a top view of a frame assembly formed from a set of framemembers and constructed to support a solar panel, according to anembodiment of the invention. A frame assembly 400 may be rectangular, soas to include frame members that are referenced as horizontal members412 and vertical members 414. Reference to a horizontal and verticaldirection is arbitrary, but for purpose of an implementation beingdescribed, the vertical direction may reflect a direction of water flowas a result of gravity. To this end, the frame assembly 400 may beassumed to be mounted or for mounting on an incline surface, althoughincline mounting is not necessary. In one implementation, verticalmembers 414 are aligned and coupled to support rails 135 (FIG. 1). Therails 135 (see FIG. 1A) may employ compression to retain the solarmodules in place. For example, U.S. patent application Ser. No.11/332,000 (which is incorporated by reference herein) describes a railconstruction that uses compression to retain a solar module. As verticalmembers 414 may form a part of the rails and thus compress the solarmodules, the vertical members may inherently weather-guard or seal edgeswhere the solar modules are held.

In an embodiment, individual horizontal members 412 include one or moresealing features that serve to weather-guard the solar module to solarmodule transition in the vertical direction. The sealing features mayinclude or correspond to a structural feature that is integrated intothe frame member 412. In one embodiment, each horizontal frame member412 includes one of an overlap frame thickness 422 (e.g. protrusion) ora recess platform 424 for receiving an overlap protrusion. As describedin an embodiment of FIG. 5A and FIG. 6, frame assembly 400 may beconfigured to position the recess platform 424 adjacent and downhill (inthe vertical direction) from an overlap frame thickness of an adjacentframe member that is part of another uphill set of frame members.Likewise, frame assembly 400 may be configured to position the overlapframe thickness 422 uphill from a recess platform of an adjacent set offrame members.

FIG. 5A is a side-cross sectional view of a first pair of adjoininginterior frame members in an assembly for a solar module array,according to an embodiment of the invention. The pair of adjoininginterior frame members include a first interior frame member 510 and asecond interior frame member 560. When mounted on an incline, secondinterior frame member 560 is uphill from the first interior frame member510, as shown by an Arrow A. Each interior frame member 510, 560 isstructured to hold and support a corresponding solar collective panel520. The panel 520 may correspond to, for example, laminate forphotovoltaic panels, or a glazing element for thermal modules.

The various members of the first interior frame member 510 form anopening 515 that receives the corresponding solar panel 520. The opening515 may be formed by an underside 513 of an exterior segment 514, aspositioned over a base segment 517. A first height segment 519 mayextend from base segment 517 partially towards exterior segment 514. Thefirst wall (or height segment) 519 may join a platform segment 521,which may extend parallel or substantially parallel to the base segment517. A second wall 523 may extend from the platform segment 521 to theexterior segment 514.

The space defined by the distance between the platform segment 521 andthe base segment 517 may define an opening 518 which is smaller than adimension of the cross section of the solar panels 520. In this regard,the opening 518 serves as a buffer space to enable the use of a recessplatform surface 525 of the platform segment 521 to receive an extensionmember from the second interior frame member. Furthermore, each interiorframe member 510, 560 may extend to and couple to other orthogonallyaligned frame members (See FIG. 4), and therefore leverage support fromone of the corresponding rails 135 to support the solar module.

A depth distance (d1) of the recess platform surface 525 may be measuredas corresponding to a height of the second wall 523 (and a distance toan exterior surface 511 provided by the exterior segment 514). The depthdistance d1 may be greater than or substantially equivalent to athickness dimension of an extension provided by the second interiorframe segment 560.

The second interior frame member 560 includes an opening 568 having anextended exterior segment 562, a wall segment 563, and a base segment565. A space between the base segment 565 and the extended segmentmember 562 defines the opening 568 where the corresponding solar panel520 is received and supported. In an embodiment, the wall segment 563extends sufficiently from the base segment 565 so that the extendedexterior segment 562 is positioned above the raised platform surface 535of the adjacent first interior frame segment 510. In an embodiment, athickness (d2) of the extended exterior segment 562 is dimensioned to beless than the depth distance (d1) provided by the recess platformsurface 525. In this way, the extended exterior segment 562 may beaccommodated over the recessed platform surface 525. Moreover, thedimension of the depth distance (d1) and the thickness (d2) of theextended exterior segment 562 may be such that the exterior surface 511of the exterior segment 514 of the first interior frame member 510 issubstantially flush with the exterior surface 561 of the extendedexterior segment 562 of the second interior frame member 560.

When mounted on an incline, the combination of the first and secondhorizontal frame members result in a shingle-like or flashing effect inwhich water is passed over the exterior of the combined structure (withsolar modules). Water may pass downhill (as shown by directional ArrowA). When mounted at an incline, water may pass from the second solarmodule 520 to the first solar module, and any water that falls in a gap575 formed by the joining of the first and second horizontal framemembers will not be inclined to travel uphill on the recessed platformsurface 525. An interior space 577 may thus be substantially protectedfrom intrusion of water, even when water cascades over the combinedsurfaces formed by the solar panels 520 and frame members.

FIG. 5B is a side-cross sectional view of a second pair of adjoininginterior frame members in an assembly for a solar module array,according to an embodiment of the invention. FIG. 5B may substantiallyduplicate an embodiment such as shown by FIG. 5A, but illustrate a pointthat the frame assembly of any one solar panel 520 may include both therecessed platform surface 525 and the extended exterior segment 562which provides a thickness that is received on a recessed platformsurface on the frame assembly of a neighboring solar panel. In anembodiment of FIG. 5B, the solar panel (“B”) of the second interiorframe member is shown having the receiving platform surface 525 (asshown and described with FIG. 5A for the first interior frame member510). Thus, any given solar panel 520 may include the recess platformsurface 525 on one frame member that is uphill on an inclined array, andthe extended exterior segment 562 at the other diametric frame memberpositioned downhill on the inclined array.

FIG. 6 is an isometric view of an embodiment such as shown by FIG. 5Aand FIG. 5B, without inclusion of solar panels 520. The interior framemembers 510, 560 may form a joining through structures formed on eachrespective frame member. The first frame 510 includes an exteriorsegment 514, base segment 517, first wall 519 which raises to platformsegment 521. The recessed platform surface 525 may be formed on theplatform segment 521. The second wall 523 may extend form the recessedplatform surface 525 to the exterior segment 514. The second interiorframe member 560 includes extended exterior segment 562 that overlapsonto the recessed platform surface 525. The opening 568 (FIG. 5A) may bedefined by a portion of the extended exterior segment 562 and the base565.

In an embodiment such as shown by FIG. 6, the extended exterior segment562 of the second interior segment 560, and the manner in which theexterior segment 562 is accommodated onto the recessed platform 525 ofthe first interior segment 510, provides one form of an overlap framethickness from which a shingle or flashing affect may be provided. Stillfurther, gaskets or other materials may be used to further seal thejoining formed with the overlap frame thickness. With loose fitting,some water may enter the gap 575 (see FIG. 5A), but the water may beprecluded or inhibited from traveling across recessed platform surface525, particularly when an incline mount is used. With tight fitting,gaskets or other structures, seal may be formed that substantiallyprecludes water from entering the sealed portion within the gap 575 evenwhen the arrays are mounted level instead of on an inclined surface.

Alternatives to Structuring of Frame Members

FIG. 7 illustrates an alternative embodiment in which an additionalcomponent or member is provided to seal or provide flashing betweenadjoining frame members, according to one or more embodiments of theinvention. Rather than include flash/counter-flash structures with framemembers (e.g. recess and overlap), an embodiment of FIG. 7 provides foruse of a gap member 710 that extends between rail members or othersupports (not shown in FIG. 7) that support adjacent solar modules. Inan embodiment, the gap member may include a T-shape cross section, sothat a length of the member fits within a gap formed by adjacenthorizontal frame members. In contrast to, for example, embodiments ofFIG. 5A, FIG. 5B, and FIG. 6, the surfaces of adjoining interior membersmay be relatively smooth to receive and retain a length segment 712 ofgap member 710. A flange 714 may extend between the pair of adjacentinterior members to block the entrance of water into the gap 720.Additional weatherproofing may be achieved by placing a gasket betweensegment 712 or flange 714 and the mating frame members

FIG. 8 illustrates an alternative embodiment in which a gasket orsimilar component is fitted or applied into a gap between the horizontalframe members of adjacent solar modules, according to one or moreembodiments. In contrast to, for example, embodiments of FIG. 5A, FIG.5B, and FIG. 6, the surfaces of adjoining interior members may berelatively smooth to form a gap 820. The gap 820 may receive a gasketcomponent 810, filler or other form of deformable material. The effectis to seal the gap 820, thereby enabling water to pass from one solarmodule to another without entering an interior space of the arraybeneath the solar modules. The gasket component 810 may flange or spreadover adjoining frame members to provide a seal.

Uphill Flashing and Water Guide

With reference to FIG. 2, solar module arrays are often mounted oninclines. In such cases, rain water and precipitation can collect on atop surface. A perimeter flashing or seal (such as described in U.S.patent application Ser. No. 11/332,000) may be used to preclude orinhibit rain water from entering the interior of the solar module arrayfrom a perimeter surface. But water may pool at the top end of thearray, and on structures such as rooftops, the pooling may haveundesirable consequences.

According to an embodiment, the effects of pooling may be mitigated oreven eliminated by enabling water to cascade downhill over the array ofsolar modules. With reference to an embodiment of FIG. 2, water may flowalong a directional arrow B. As described herein, embodiments such asdescribed with FIG. 4-7. The use of flashing or sealing between framemembers that support solar panel modules enables the water to pass overthe adjoining solar modules without intrusion of water into the interiorspace of the array beneath the solar module.

FIG. 9 illustrates an embodiment in which flashing and other structuresare used to guide water over the solar modules. A flashing component 930may be installed under a roof covering 905 and extended to overlay thesolar module array 900. This results in water running down the roof tobe conveyed from the roof covering 905 up onto the array 900. In oneembodiment, the flashing component may include two sections (i.e.flashing and counter-flashing). One benefit provided by flashingcomponent 930 is that it eliminates the pooling of water, snow, ice, orother debris behind (i.e. adjacent top side 102) the solar module array900.

Electrical Connectivity

One or more embodiments provide interlocking solar modules thatelectrically connect during the assembly of individual modules into theracking structure for a given solar array. Such embodiments mayeliminate a secondary step of having to hand-connect the wiring (bothmodule potential and grounding) after the modules are physically placed

According to one or more embodiments, the electrical connectors areembedded in the frames of the modules, such that when two modules areslid together during assembly, the electrical interconnections betweenadjacent modules are simultaneously formed.

FIG. 1A illustrates one alignment of electrical wiring or lines for anarray of solar modules. In one embodiment, the electrical line mayextend in a direction of the rail 135 or other support structure. Asdescribed, each solar module includes electrical connectors forextending electrical connectivity to an adjacent solar panel.

FIG. 10 is a side view of adjacent solar modules having integratedelectrical connectivity extending therebetween, under an embodiment ofthe invention. A first solar module 1010 may include a panel 1012 and aframe member 1014. Likewise, a second solar module 1060 may include apanel 1062 and a frame member 1064. Each of the solar modules 1010 and1060 may include a respective integrated electrical connector 1020,1070. The electrical connectors 1020, 1070 may provide respectiveelectrical leads or wiring. The connectors 1020, 1070 (as well asconduits for the leads) are integrated through holes 1015, 1065 formedin the respective frame members 1014, 1064. The connectors 1020, 1070may each be secured by a locking nut on the opposite side of therespective frame member 1014, 1064 to hold them captive. In alternateconfigurations, the connectors may be press fit, snapped, or otherwisesecured into the module frames or the solar panels themselves.

FIG. 11 is an isometric view of an embodiment of FIG. 10, illustratinguse of the integrated electrical connectors 1020, 1070 (not visible inFIG. 11) formed in frame members 1014, 1064. Each frame member 1014,1064 may include an inward extension 1034, 1064 in which the holes 1015,1065 may be formed for receiving and retaining the respective electricalconnectors 1020, 1070. An embodiment such as shown and described withFIG. 10 and FIG. 11 may incorporate features or components of otherembodiments described herein. In particular, the electrical connectors1020, 1070 may be integrated into frame members 1014, 1064 that includestructures of an overlap frame thickness 1080 and a recessed platform1090 for receiving the overlap thickness. As described with or similarto, for example, an embodiment of FIG. 4, FIG. 5A and FIG. 5B, overlapframe thickness 1080 and recessed platform 1090 may seal or hinderintrusion of water or other environmental factors.

While an embodiment shown with FIG. 10 and FIG. 11 assumes that theconnections are made during lateral assembly of the modules, alternateconfigurations are possible. One such configuration may have theconnectors oriented in a vertical arrangement requiring the modules tobe laid in from a vertical direction on their common edge as opposed tolaterally sliding the modules together. In such an arrangement,connectors are oriented to line up with connectors on adjoining modulesso that lower modules connect to modules above them.

Only one set of connectors between modules are required for powering thesystem if the modules are series connected as is typical, but a secondset can be used as a grounding loop. Alternately, a single multi-poleconnector could be used to provide multiple electrical connections at asingle location.

CONCLUSION

Although the descriptions above contain many specifics, these should notbe construed as limiting the scope of the invention but as merelyproviding illustrations of some embodiments.

1. A frame assembly for a solar panel, the frame comprising: a pluralityof frame members that are structured to collectively support and hold afirst solar module; wherein at least one of the plurality of framemembers is structured to adjoin a frame member of a second solar modulein forming a joining with the frame member of the second solar moduleover a length where the frame member of the first and second solarmodule adjoin.
 2. The frame assembly of claim 1, wherein the joiningformed by the at least one of the frame members and the frame member ofthe second solar module substantially precludes intrusion of at leastone of external air or water into a space underlying the first moduleand the second module at the length where the frame member of the firstand second solar module adjoin.
 3. The frame assembly of claim 1,wherein the at least one of the plurality of frame members is shaped toreceive an overlap frame thickness that extends from the frame member ofthe second solar module in forming the joining.
 4. The frame assembly ofclaim 3, wherein the at least one of the plurality of frame membersincludes a perimeter recessed platform that extends lengthwise on the atleast one of the frame members, wherein the recess platform isdimensioned to receive the overlap thickness extending from the framemember of the second solar module.
 5. The frame assembly of claim 4,wherein the recessed platform is provided against an exterior surface ofthe at least one frame member, the exterior surface extending lengthwiseon the at least one of the frame members, and wherein a depth distancebetween the recessed platform and the exterior surface is substantiallyequivalent or less than a dimension of the overlap frame thickness. 6.The frame assembly of claim 1, wherein the at least one of the pluralityof frame members is shaped to extend an overlap frame thickness to theframe member of the second solar module in forming the joining with theframe member of the second solar module.
 7. The frame assembly of claim4, wherein another of the plurality of frame members is structured toadjoin a frame member of a third solar module in forming a joining withthe frame member of the third solar module over a length where the framemember of the first and third solar module adjoin.
 8. The frame assemblyof claim 7, wherein the another of the plurality of frame members isshaped to extend an overlap frame thickness to the frame member of thethird solar module in forming the joining with the frame member of thethird solar module.
 9. The frame assembly of claim 8, wherein one ormore of the frame members includes an integrated electrical connector.10. A frame assembly for a solar panel, the frame comprising: aplurality of frame members that are structured to collectively supportand hold a first solar module; wherein the plurality of frame membersincludes a first frame member that provides an overlap frame thickness adistance outward from the first frame member, wherein the overlap framethickness is extended outward in a lengthwise direction of the firstframe member; and wherein the plurality of frame members includes asecond frame member that includes a perimeter recessed platform that isextended in a lengthwise direction of the second member, wherein therecessed platform is provided against an exterior surface of the secondframe member to define a depth distance between the recessed platformand the exterior surface.
 11. The frame assembly of claim 10, wherein adimension of the overlap frame thickness is substantially equivalent tothe depth distance.
 12. The frame assembly of claim 10, wherein thefirst frame member and the second frame member are provided on oppositesides of a rectangular support frame formed by the plurality of framemembers.
 13. The frame assembly of claim 10, wherein one or more of theframe members includes an integrated electrical connector.
 14. The frameassembly of claim 10, further comprising a primary support structure,wherein the primary support structure support a plurality of solarmodules in a raised and inclined position over an underlying body.
 15. Asolar module assembly comprising: a plurality of solar modules; a frameassembly comprising a plurality of frame members, the plurality of framemembers including multiple sets of frame members, wherein each set offrame members combines to support a corresponding solar module inposition; wherein the plurality of frame members include a pair ofadjoining frame members, the pair of adjoining frame members include aframe member of a first set of frame members that adjoins a frame memberof a second frame member; a sealing feature provided for the pair ofadjoining frame members to substantially preclude intrusion of at leastone of external air or water into a space underlying a solar module ofthe first set or of the second set.
 16. The solar assembly of claim 15,wherein the sealing feature includes a gasket provided between the framemember of the first set of frame members and the frame member of thesecond set of frame members.
 17. The solar assembly of claim 15, whereinthe sealing feature includes a sealing member that is separate from thepair of adjoining frame members.
 18. The solar assembly of claim 17,wherein the sealing member extends lengthwise between the pair ofadjoining frame members and extends a length at least partially into agap formed between the pair of adjoining frame members.
 19. The solarassembly of claim 18, wherein the sealing member has a T-shapecross-section.
 20. The solar assembly of claim 15, wherein the sealingfeature comprises: an overlap frame thickness extending from one of thepair of adjoining frame members, the overlap frame thickness extendingoutward and along a lengthwise direction of that one of the pair ofadjoining frame members; a recessed platform provided on a perimeter ofthe other one of the pair of adjoining frame members, the recessedplatform extending in a lengthwise direction of the other one of thepair of adjoining frame members, wherein the recessed platform isprovided against an exterior surface of the other one of the pair ofadjoining frame members, and wherein the recessed platform isdimensioned to receive the overlap frame thickness.
 21. The solarassembly of claim 20, wherein a depth distance between the recessedplatform and the exterior surface is substantially equivalent to or lessthan a dimension of the overlap frame thickness.
 22. The solar assemblyof claim 15, further comprising a primary support structure that securesthe plurality of frame members to an underlying body, and wherein theprimary support structure and the plurality of frame members combine tosupport a plurality of solar modules in a raised and inclined positionover the underlying body.
 23. The solar assembly of claim 22, whereinthe primary support structure includes one or more rails that usecompression to secure at least a portion of a corresponding solar moduleto the underlying body.
 24. The solar assembly of claim 23, wherein theprimary support structure forms at least a portion of a perimeter thatincludes one or more of a lateral side, a top side, or a bottom side,and wherein anyone of the individual frame members that form the pair oflateral sides, the top side or the bottom side are provided with one ormore features that form a seal with the underlying body.
 25. The solarassembly of claim 24, wherein the primary support structure includes oneor more corner frame components that individually connect a supportstructure member that forms at least a portion of the top side with asupport structure member that forms at least a portion of one of thepair of lateral sides.
 26. The solar assembly of claim 25, wherein theone or more corner elements are provided with one or more features toseal each of the one or more corner elements to the underlying body. 27.The solar assembly of claim 24, wherein the primary support structure isstructured or provided flashing to facilitate flow of water from the topside downward over one or more of the solar modules.
 28. The solarassembly of claim 15, wherein one or more of the plurality of framemembers each include or are coupled to an integrated electricalcomponent that is positioned to mate with an integrated electricalcomponent of an adjacent frame member.
 29. The solar assembly of claim28, wherein a frame member of a first set of frame members includes oris coupled to a first integrated electrical connector, and wherein aframe member of a second set of frame members includes or is coupled toa second integrated electrical connector, wherein a solar module of thefirst set of frame members is positioned adjacent to a solar module ofthe second set of frame members, and wherein the first integratedelectrical connector is positioned to mate with the second integratedelectrical connector with assembly of the first set of frame members andthe second set of frame members.
 30. The solar assembly of claim 15,wherein the plurality of solar modules include at least one or morethermal modules.